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ABB HT563322 Operation Manual

Turbocharging
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Operation Manual
Type TPL65-A36
n
Mmax
n
Bmax
SISO20
Year
ABB Turbo Systems Ltd
TPL65-A36
ABB Turbo Systems Ltd
CH 5401 Baden
467
1/s
444
01230
kg
2016
made in Switzerland
HT563322
t
680
Mmax
t
650
Bmax
35
50
50
Application according to
the Operation Manual
Turbocharging
°C
Table of Contents
loading

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Summary of Contents for ABB HT563322

  • Page 1 Turbocharging Operation Manual TPL65-A36 ABB Turbo Systems Ltd CH 5401 Baden Type TPL65-A36 HT563322 Mmax Mmax °C Bmax Bmax SISO20 01230 Application according to Year 2016 the Operation Manual made in Switzerland ABB Turbo Systems Ltd...
  • Page 2 „European Machinery Directives“. We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without express authority by ABB Turbo Systems Ltd is strictly forbidden. © Copyright by ABB TURBO SYSTEMS Ltd 2004 Design and specifi...

  • Page 3: Table Of Contents

    Periodic checking of the pressure vessel Lifting loads Commissioning Oil supply Inspection work Commissioning after taking out of operation Operation Noise emissions Servicing work Replacement intervals for turbocharger components Speed measurement Stopping the engine © Copyright 2014 ABB. All rights reserved.
  • Page 4 Turbine-end removal / fitting of the nozzle ring Table of tightening torques Taking out of operation at short notice Possibilities for emergency repair Locking the rotor Fit cover plate Blocking the inlets and outlets Bypass the turbocharger © Copyright 2014 ABB. All rights reserved.
  • Page 5 View of cartridge group with part numbers TPL65-A32 / -A33 / - 12.3 12.4 View of cartridge group with part numbers TPL69-A32 / -A33 12.5 View of turbine cleaning system with part numbers (optional) © Copyright 2014 ABB. All rights reserved.

  • Page 7: Preliminary Remarks

    Operation Manual This Operation Manual enables you to familiarize yourself with the turbocharger supplied by ABB Turbo Systems and to use it as intended. It provides important information in order that the turbocharger can be operated safely, correctly and efficiently.

  • Page 8: Layout And Function

    2 Radial plain bearing 9 Turbine wheel 3 Thrust bearing 10 Bearing casing 4 Bearing bush 11 Diffuser 5 Radial plain bearing 12 Compressor wheel 6 Gas outlet casing 13 Compressor casing 7 Gas inlet casing © Copyright 2014 ABB. All rights reserved.
  • Page 9 The plain bearings are connected to a central lubricating oil channel which is fed with oil from the engine lubrication circuit. The oil outlet is always at the lowest point of the bearing casing (10). © Copyright 2014 ABB. All rights reserved.
  • Page 10 In the case of the turbocharger version with compressor wheel cooling, the cooling air is supplied through the side connection (15) in the bearing casing. © Copyright 2014 ABB. All rights reserved.

  • Page 11: Correct Use Of The Turbocharger

    Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Systems reserves the right to reject all warranty claims.

  • Page 12: Storage Of New Turbochargers And Spare Parts

    Storage of new turbochargers and spare parts up to 6 months New turbochargers and cartridge groups from ABB Turbo Systems can be stored in sealed packaging without additional mothballing measures for up to 6 months from the date of delivery (marked by the VCI label on the packaging).
  • Page 13 Page 11 spare parts Long-term storage of replacement turbochargers or spare parts Per order, turbochargers or cartridge groups will be prepared by ABB Turbo Systems for prolonged storage. The package is equipped with a hygrometer (see the figure). The following measures are required every 6 months: Check the hygrometer (2) in the sight-glass.

  • Page 14: Essential Information

    The fault must be reported to the person or department responsible. Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Systems. NOTICE © Copyright 2014 ABB. All rights reserved.
  • Page 15 The turbocharger may be operated and maintained only by trained and authorized personnel. Work on mechanical components, such as bearings or rotors, may be carried out only by trained fitters from an official ABB Turbocharging service station. CAUTION © Copyright 2014 ABB. All rights reserved.
  • Page 16 Differences may exist in certain details. Registered Trademarks Registered trademarks of external companies are used in this document. The trademarks are marked with ®. © Copyright 2014 ABB. All rights reserved.

  • Page 17: Symbols And Definitions

    Definition of caution / warning The caution and warning signs are described in the chapter Safety. ABB Turbo Systems In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems. Official ABB Turbo Systems service stations In this document, official service stations are referred to as ABB Turbocharging Service Stations.

  • Page 18: Turbocharger Rating Plate

    Replacement interval for compressor in 1000 h turbocharger components Replacement interval for turbine in 1000 h Further information Part number for customer Designation of special design Turbocharger weight in kg Turbocharger type Serial number Year of turbocharger construction © Copyright 2014 ABB. All rights reserved.
  • Page 19 A rating plate is attached to the turbocharger foot, one on the left and one on the right. In the case of turbochargers with insulation supplied by ABB Turbo Systems, at least one additional rating plate is attached to the insulation of the gas outlet casing.

  • Page 20: Contact Address And After-Sales Service

    ABB Turbo Systems AG Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging After-sales service Official ABB Turbo Systems Service Stations A list of the service stations is available in the brochure "Contact Information" or online. © Copyright 2014 ABB. All rights reserved.

  • Page 21: Safety

    Page 19 Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger...

  • Page 22: Definition Of Mandatory Signs

    Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either CAUTION not followed or not followed precisely. Caution signs must be observed at all times.  © Copyright 2014 ABB. All rights reserved.

  • Page 23: Warning Plates On The Turbocharger

    Warning plates on the turbocharger Page 21 Warning plates on the turbocharger Warnings that have been attached to turbochargers by ABB Turbo Systems must not be removed. Illegible warnings must be replaced with new ones. Further information is available from ABB Turbocharging service stations.

  • Page 24: Safe Operation And Maintenance

    Remove combustible objects and substances out of the range of flying  sparks. Cover all connections on the turbocharger so that no foreign objects  can get into the turbocharger. © Copyright 2014 ABB. All rights reserved.
  • Page 25 Protect the floor against unintentional penetration of detergents or  solvents before starting cleaning operations. Wear appropriate protective clothing.  Inspect the electric cables for abrasion and damaged areas before and  after your cleaning work. © Copyright 2014 ABB. All rights reserved.
  • Page 26 Secure the rotor so it cannot turn. The rotor can turn on its own from  the force of the stack draught. Clean the turbocharger before mothballing it.  Wear appropriate protective clothing.  © Copyright 2014 ABB. All rights reserved.

  • Page 27: Hazards During Operation And Maintenance

    Heed the general rules for work safety and accident prevention.  Ensure the safety of the work area.  Perform only those tasks that are described in this manual.  Perform work only for which training has been carried out.  © Copyright 2014 ABB. All rights reserved.
  • Page 28 Wear safety gloves against thermal risks. Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied by ABB Turbo Systems without insulation WARNING depending on the order from the engine builder. In this case, the engine builder is responsible for insulating the turbocharger properly or for providing protection against hot surfaces being touched.
  • Page 29 The escape of operating and auxiliary materials into the atmosphere or contamination of the ground and water due to improper disposal can CAUTION lead to environmental damage. Handle operating and auxiliary materials carefully.  © Copyright 2014 ABB. All rights reserved.
  • Page 30 Remove packing materials only in the work area.  Take particular care when removing old insulating materials.  Dispose of insulating materials properly and in an environmentally  compatible way in accordance with applicable local regulations. © Copyright 2014 ABB. All rights reserved.

  • Page 31: Periodic Checking Of The Pressure Vessel

    Heed any country-specific regulations.  Periodic checking of the pressure vessel The pressure vessels used by ABB Turbo Systems, such as those for wet or dry cleaning, are so-called "simple pressure vessels".  The local, statutory regulations covering periodic checks of pressure vessels must be observed.

  • Page 32: Lifting Loads

    Completely screw in assembly / fitting devices without fail so that they  cannot work loose during use. Use assembly / fitting devices only for applications described.  Make sure removed turbocharger components stand safely and  securely. © Copyright 2014 ABB. All rights reserved.

  • Page 33: Commissioning

    NOTICE Oil filtration A lubricating oil filter system with a filter mesh size of ≤ 0.034 mm is adequate for this turbocharger. © Copyright 2014 ABB. All rights reserved.
  • Page 34 To make sure these oil pressures are obtained, a regulating orifice is fitted in the turbocharger oil inlet. The orifice is fitted by the engine NOTICE builder and secured by a safety ring. © Copyright 2014 ABB. All rights reserved.
  • Page 35 > 160 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2014 ABB. All rights reserved.

  • Page 36: Inspection Work

    Failure of compressor wheel cooling system The service life of the compressor wheel will be impaired if the breakdown of the compressor wheel cooling system lasts long. CAUTION Ensure supply of cooling air.  © Copyright 2014 ABB. All rights reserved.
  • Page 37 If oily liquid continues to escape after this period, an oil leak must be suspected. The first step is to check for leakage of the oil NOTICE supply to the turbocharger. If this is leaky, contact an official ABB Turbocharging service station. 3.2.4 Inspection after 100 service hours Clean or replace lubricating oil filters after the first 100 service hours.

  • Page 38: Commissioning After Taking Out Of Operation

    / commissioning" of chapter headed "Start-up / commissioning". Start up turbocharger.  TPL65: Version with compressor wheel cooling system Remove screw plug on cooling air connection and fit cooling air line.  © Copyright 2014 ABB. All rights reserved.

  • Page 39: Operation

    Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level In the event of divergent insulation designs, the engine builder must ensure that equivalent acoustic insulating measures are taken. © Copyright 2014 ABB. All rights reserved.
  • Page 40 Suggestion for noise insulation of the bellows A Compressor casing D Insulation pads B Bellows E Insulation mat (at least 15 mm) C Charge air duct / scavenging air F Sheet-metal cover pipe © Copyright 2014 ABB. All rights reserved.

  • Page 41: Servicing Work

     Systems. Service inspection after 5 years To prevent age- and stoppage-related machine damage, an inspection by an ABB Turbocharging Service Station is recommended at the latest NOTICE 5 years after the last service. 4.2.1 Service work every 25 … 50 hours Check visually for air, exhaust gas, water and oil leaks.
  • Page 42  Pressure loss in air filter 4.2.3 Servicing work according to the engine manufacturer's instructions Clean or replace oil filter in supply line to turbocharger when engine is Oil filter  not running. © Copyright 2014 ABB. All rights reserved.
  • Page 43 Inspect and assess bearing parts and rotor.  4.2.5 Service work every 24000 … 36000 hours The replacement of bearing parts as well as the inspection and assessment of the rotor must be carried out by an ABB Turbocharging Service Station. Disassemble turbocharger.  Measure clearances.

  • Page 44: Replacement Intervals For Turbocharger Components

     Turbine cleaning frequency  Procedure for turbine cleaning Parameters influencing rotating components exposed to exhaust gas  Fuel quality (Gas, MDO, HFO)  Turbine cleaning frequency  Procedure for turbine cleaning  Loading profile © Copyright 2014 ABB. All rights reserved.
  • Page 45 See the data on the rating plate replacement intervals [h] = Gas Engine = Marine Diesel Oil = Heavy Fuel Oil See Influencing The specified values are guides and not guaranteed. ( parameters NOTICE © Copyright 2014 ABB. All rights reserved.

  • Page 46: Speed Measurement

    Cable connector for 86505 86526 F/I converter 86528 Tachometer 4.4.1 Speed differences with multiple turbochargers per engine The speeds of all turbochargers on one engine differ only slightly from each other in normal operation. © Copyright 2014 ABB. All rights reserved.
  • Page 47 If the engine can be stopped for a short time: Inspect the air and gas lines as well as the turbocharger and eliminate  any problems. In any event, it is recommended that you contact the nearest ABB  Turbocharging Service Station. 4.4.2...
  • Page 48 Join up cable connector and speed sensor.  Switch on lubricating oil supply to turbocharger.  4.4.4 Failure of speed measuring system Possible reasons for failure of the speed measuring system are described in the chapter Troubleshooting. © Copyright 2014 ABB. All rights reserved.

  • Page 49: Stopping The Engine

    Before the engine is shut down, it must be allowed to idle for about 5 to 10 minutes so that the circulating lubricating oil can take away heat from the turbocharger bearings. CAUTION © Copyright 2014 ABB. All rights reserved.

  • Page 51: Maintenance

     The safety precautions must be observed during all maintenance and servicing work. The cleaning points described in the following are:  Filter silencer  Compressor  Turbine and nozzle ring © Copyright 2014 ABB. All rights reserved.

  • Page 52: Cleaning The Filter Silencer

    81265 Filter strip (if provided) 81136 Absorption segment 81269 Connecting rods 81137 Cover sheet metal 81266 Cover grid 81135 Filter silencer body 81272 Screw 81273 Lock nut E Insert unit = absorption segment + cover sheet metal © Copyright 2014 ABB. All rights reserved.
  • Page 53 Otherwise there is a risk of damage or change of shape. Replace very dirty or damaged parts with original parts from ABB Turbo Systems. NOTICE...
  • Page 54 If the connecting rods (81269) are not located correctly in their recesses on the filter silencer body (81135), the cover sheet metal (81266) can turn and shift. There is then a risk of foreign matter and dirt getting into the compressor. CAUTION © Copyright 2014 ABB. All rights reserved.
  • Page 55 (81272) to following maximum torque: Screw tightening torque [Nm] 81272 Screw lock nuts (81273) onto screw (81272) and tighten to following  torque: Lock nut tightening torque [Nm] 81273 Fit filter strip (81265). If provided  © Copyright 2014 ABB. All rights reserved.

  • Page 56: Cleaning The Compressor During Operation

    Cleaning interval conditions. In general, cleaning should be carried out every 25 to 100 operating hours. Cleaning intervals Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems. NOTICE © Copyright 2014 ABB. All rights reserved.
  • Page 57 Cleaning of the compressor during operation is carried out using the cleaning method described in the following:  Wet cleaning This cleaning method has been tested and approved by ABB Turbo Systems. To clean the compressor stage while in operation, water is injected in front...
  • Page 58 Operating state prerequisites for cleaning compressor with XC2 To be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled: Engine load 50 … 85% ...
  • Page 59 Operating state prerequisites for compressor cleaning with XC3 To be able to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Systems, the following prerequisites must be fulfilled: Engine load 50 … 85% ...
  • Page 60 If the cleaning results are still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that you have NOTICE the turbocharger inspected and cleaned by an official ABB Turbocharging Service Station. Cleaning parameters per turbocharger compressor...

  • Page 61: Cleaning Turbine Blades And Nozzle Ring In Operation

    If cleaning is carried out correctly and the cleaning system is properly sized, however, the intervals between overhauls can be extended. © Copyright 2014 ABB. All rights reserved.
  • Page 62 When cleaning the turbine components during operation, use wet Cleaning method cleaning. This cleaning method has been tested and approved by ABB Turbo Systems. Prerequisites for wet cleaning are that the engine builder approves the process and his instructions are followed.
  • Page 63 Recommended operating state for turbine wet cleaning The following operating state and prerequisites have been tested and approved by ABB Turbo Systems for the cleaning process: The engine has just been started or the engine load has been reduced ...
  • Page 64 Finish injection procedure this way.  Close drain hole (if provided) above drain pipe (8,9).  After cleaning, wait with engine running for at least 10 minutes without  changing load to allow turbocharger to dry. © Copyright 2014 ABB. All rights reserved.
  • Page 65 The maximum volume of water allowed in individual cases must be determined together with an ABB Turbocharging service station. The influence of the cleaning water on peripheral equipment, such as a boiler, must be clarified by the operator.

  • Page 67: Troubleshooting

    Certain tolerances must be observed to avoid a significant loss of efficiency.  If there is any doubt about the extent of rubbing, then an ABB Turbocharging Service Station must be contacted.  Have a dimension check carried out by an ABB Turbocharging Service Station.

  • Page 68: Surging Of The Turbocharger

    Prolonged or periodic surging Possible damage to components, such as the compressor wheel, turbine blades, bearings and filter silencer CAUTION Have the cause clarified immediately by an ABB Turbocharging  service station and rectified. Have components inspected for damage and, if necessary, replaced ...

  • Page 69: Malfunctions During Operation

    Clean it. Defective oil pump in Check / replace it. lubricating system Manometer display wrong. Replace manometer. Turbocharger Rotor axial clearance too large Contact ABB Turbocharging service station. Drop in speed Possible causes Elimination Engine Defects of connected Contact engine builder.
  • Page 70 Charge air Dirty cooler Clean it. cooler Cooling water volume too Top up water. small Entry temperature of cooling Inspect / clean cooling system. water too high Inadequate ventilation Improve ventilation. © Copyright 2014 ABB. All rights reserved.
  • Page 71 Engine performance and engine speed unchanged, suction condition normal Possible causes Remedy Engine Malfunction in the injection Repair or contact manufacturer system Injection misaligned Set correctly Engine performance higher Check engine performance than expected Turbocharger Manometer display defective Replace manometer © Copyright 2014 ABB. All rights reserved.

  • Page 72: Malfunctions When Stopping

    Touching rotor Foreign matter in turbocharger Run-down time too short Possible causes Elimination Turbocharger Dirty turbocharger Clean it. Damaged bearing Contact ABB Turbocharging service station. Touching rotor Foreign matter in turbocharger © Copyright 2014 ABB. All rights reserved.

  • Page 73: Speed Measurement System

    This problem is eliminated by removing the gasket. Defective sensor Contact ABB Turbocharging service station. Measured Dirty sensor tip The sensor tip is magnetic and can thus speeds too attract metal particles.

  • Page 75: Removal And Installation

    The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, depending on the specification. Weights [kg] TPL65-A32/-A33/ -A36 TPL69-A32 / -A33 1230 1780 © Copyright 2014 ABB. All rights reserved.

  • Page 76: Remove The Turbocharger

    Remove the air supply line. (Also see the chapter Preliminary remarks  / Layout and functioning.) Inspect the lifting gear.  Fasten separate lifting gear to each of the two ribs on the bearing  casing provided for this purpose. © Copyright 2014 ABB. All rights reserved.
  • Page 77 WARNING serious or even fatal injury. Support the turbocharger at a suitable point.  If possible secure it using lifting gear.  Wear safety helmet. Cover the oil connection.  © Copyright 2014 ABB. All rights reserved.

  • Page 78: Installing The Turbocharger

    TPL65: Version with compressor wheel cooling system Fit air supply line. (See also chapter Preliminary remarks / Layout and  functioning.) Refit removed parts of insulation.  Plug in cable connector on speed sensor.  © Copyright 2014 ABB. All rights reserved.

  • Page 79: Disassembly And Assembly

    CAUTION Only carry out those tasks that are described in this chapter.  Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions are marked before disassembling the turbocharger. NOTICE Identifying assembly devices Not all assembly devices are marked with a part number. They can be identified using the tool list.
  • Page 80 They are not commercially available products. Use assembly / fitting devices only for the applications described.  Lifting gear Equipment for lifting and transporting loads (ropes, chain hoists, cranes). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2014 ABB. All rights reserved.

  • Page 81: Module Weights

    TPL65-A32 / A33 / A36 TPL69-A32 / -A33 Radial air suction branch Axial air suction branch Filter silencer Compressor casing Wall insert Diffuser Cartridge group Turbine diffuser Nozzle ring 10 Radial gas inlet casing © Copyright 2014 ABB. All rights reserved.
  • Page 82 TPL65-A32 / A33 / A36 TPL69-A32 / -A33 Complete compressor casing The total weight of the complete compressor casing is an addition of the weights of the compressor casing, the diffuser and the wall insert. NOTICE © Copyright 2014 ABB. All rights reserved.

  • Page 83: Removing And Fitting Filter Silencer Or Air Suction Branch

    Unscrew the nuts (72027) and remove them together with the washers  (72018). Remove the air suction branch and set it down to one side.  Fit the air suction branch in reverse order. Installing the air suction  branch © Copyright 2014 ABB. All rights reserved.
  • Page 84 Unscrew the nuts (72027) and remove them together with their  washers (72018). Remove the filter silencer and it set down to one side.  Fit the filter silencer in reverse order. Installing the filter silencer  © Copyright 2014 ABB. All rights reserved.

  • Page 85: Axial Clearance

    Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. © Copyright 2014 ABB. All rights reserved.

  • Page 86: Removing Cartridge Group

    Unscrew nuts (61037).  Uniformly press apart compressor casing (72000) using three press-off  nuts (61090). Slightly lift compressor casing (72000) and pull out.  Remove O-ring (42012).  © Copyright 2014 ABB. All rights reserved.
  • Page 87 Check the underlay and adjust it if necessary.  Remove the screws (72002).  Remove the diffuser (79000).  Remove the wall insert (77000) using swivel lifting eyes (90235).  Remove the O-ring (77005) from the wall insert.  © Copyright 2014 ABB. All rights reserved.
  • Page 88 If the blades have insufficient or no clearance between the rotor and the casing, this can lead to damage to the blades and the casing. Turn rotor to check that blades do not rub against turbine diffuser.  CAUTION © Copyright 2014 ABB. All rights reserved.
  • Page 89 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Removing cartridge group Page 87 Withdraw the cartridge group and fit the supports (90450).  Cover the oil connections.  © Copyright 2014 ABB. All rights reserved.

  • Page 90: Dismantling And Installing The Turbine Diffuser And Nozzle Ring

    Before removing the turbine diffuser, secure the nozzle to prevent it  CAUTION from falling. Before disassembling the turbine diffuser, if possible secure the nozzle  ring against falling with a lashing strap and a wooden block. © Copyright 2014 ABB. All rights reserved.
  • Page 91 Insert extension (A) of torque spanner (B) through clamp hole and only  loosen screws (61056) one after other. Do not yet remove the screws (61056) and Verbus Ripp® washers  (61057). © Copyright 2014 ABB. All rights reserved.
  • Page 92 Install the nozzle ring and turbine diffuser in the reverse order of  removal. Coat the screw threads with high-temperature grease.  Align nozzle ring with holes or cams in gas inlet casing.  © Copyright 2014 ABB. All rights reserved.

  • Page 93: Installing Cartridge Group

    (61058) to the specified tightening torque (see chapter Table of tightening torques). Evenly tighten screw (61059) together with Verbus Ripp® washers TPL69-A32/33  (61058) and two nuts (61037) to the specified tightening torque (see chapter Table of tightening torques). © Copyright 2014 ABB. All rights reserved.
  • Page 94 Align and fit the wall insert (77000) using the centring screw (90187).  Place the diffuser (79000) in position using the swivel lifting eye  (90235). Remove the swivel lifting eye (90235).  Fit the screws (72002).  © Copyright 2014 ABB. All rights reserved.
  • Page 95 Clearances out of tolerance and excessively worn components can be the cause of serious damage to machinery and property. CAUTION Have components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Connect oil lines and all air lines in accordance with engine builder’s ...

  • Page 96: Turbine-End Removal / Fitting Of The Nozzle Ring

    Do not fasten the lifting gear to cleaning pipes under any circumstances. CAUTION Remove two hexagon-head screws (61044) together with Verbus  Ripp® washers (61043) from the bottom section and replace them with two studs (90177). © Copyright 2014 ABB. All rights reserved.
  • Page 97 Replace the studs (90177) with hexagon-head screws (61044) and  Verbus Ripp® washers (61043). Remove lifting gear from gas inlet casing (51001).  Secure the insulation to the gas inlet casing (51001).  © Copyright 2014 ABB. All rights reserved.

  • Page 98: Table Of Tightening Torques

    Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Disassembly and assembly Table of tightening torques Page 96 Table of tightening torques © Copyright 2014 ABB. All rights reserved.
  • Page 99 Tightening torques [Nm] Item Part number TPL65-A32 / A33 / A36 TPL69-A32 / -A33 82005 M16x1.5 M16x1.5 72027 with washer 72029 61044 61056 61059 61071 (TPL69-A32/33) 61036 61037 61090 86505 M18x1.5 M18x1.5 72002 © Copyright 2014 ABB. All rights reserved.

  • Page 101: Taking Out Of Operation At Short Notice

    If the diesel engine must be capable of operation again as soon as possible after damage to the turbocharger (emergency repair), the following possibilities are available:  Locking turbocharger rotor  Fitting the cover plate  Shutting off inlets and outlets  Turbocharger bypass © Copyright 2014 ABB. All rights reserved.

  • Page 102: Locking The Rotor

    Further measures and information for operation with a blocked rotor for CAUTION 4-stroke engines.) Otherwise components that are still intact can be damaged through overheating. Shut off the oil supply in the event of lubricating oil leaking from the turbocharger. © Copyright 2014 ABB. All rights reserved.
  • Page 103 Turn compressor wheel so that locking flange hexagon aligns with  hexagon in assembly / disassembly device (90020). Tighten nuts (74027) complete with washers (72018) on compressor  casing as specified in following Table of tightening torques. © Copyright 2014 ABB. All rights reserved.
  • Page 104 Locking the rotor Page 102 Table of tightening Part number TPL65-A32 / A33 / A36 torques 72027 75 Nm 94007 25 Nm Make sure all components are clean and free from grease. CAUTION © Copyright 2014 ABB. All rights reserved.
  • Page 105 As specified in following Table of tightening torques, tighten  intermediate ring, assembly-disassembly device (90020) and locking flange (94003) using screws (94006). Tighten nuts (74027) complete with washers (72018) on compressor  casing as specified in following Table of tightening torques. © Copyright 2014 ABB. All rights reserved.
  • Page 106 Locking the rotor Page 104 Table of tightening Part number TPL69-A32 / -A33 torques 72027 105 Nm 94006 10 Nm 94007 10 Nm Make sure all components are clean and free from grease. CAUTION © Copyright 2014 ABB. All rights reserved.
  • Page 107 0.5 bar overpressure. Attention must always be paid to the speed of the undamaged turbocharger. The speed limit n given on the rating plate must not Bmax be exceeded. CAUTION © Copyright 2014 ABB. All rights reserved.
  • Page 108 TPL69 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 TPL65 TPL69 Product α 1 α 2 α 3 TPL65 + TPL69 4 x 90° 37.5° 24 x 15° © Copyright 2014 ABB. All rights reserved.
  • Page 109 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Taking out of operation at short notice Fit cover plate Page 107 Carry out the work as described in the chapter Removal and fitting. NOTICE Remove cartridge group.  © Copyright 2014 ABB. All rights reserved.
  • Page 110 Page 108 Close off opening in gas outlet casing using cover plate.  Fasten cover plate using spacer sleeves and nuts (61037).  Shut off the supply of lubricating oil to the turbocharger. CAUTION © Copyright 2014 ABB. All rights reserved.

  • Page 111: Fit Cover Plate

    The engine can be operated according to the engine builder's instructions. Attention must always be paid to the speed of the undamaged turbocharger. The speed limit n given on the rating Bmax plate must not be exceeded. CAUTION © Copyright 2014 ABB. All rights reserved.

  • Page 112: Blocking The Inlets And Outlets

    This applies to engines with one turbocharger only:  The connections are ready and pipes for the bypass are available.  Fit bypass around turbocharger.  In this respect, refer to the engine manufacturer's instructions. NOTICE © Copyright 2014 ABB. All rights reserved.

  • Page 113: Mothballing The Turbocharger

    Wear a respiratory mask to protect against gases. If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger  © Copyright 2014 ABB. All rights reserved.

  • Page 114: Taking The Engine Out Of Operation For Up To 12 Months

    Page 112 up to 12 months The rotor and bearing parts must be dismantled and subsequently  refitted by an ABB Turbocharging Service Station Clean all parts  Coat plain surfaces of steel and cast parts with anticorrosive oil ...

  • Page 115: Taking The Engine Out Of Operation For More Than 12 Months

     The turbocharger remains mounted on the engine.  The turbocharger casing remains mounted on the engine, but the rotor and the bearing parts are removed by an ABB Turbocharging Service Station and stored separately.  The turbocharger is removed completely, either as a whole or in individual parts.

  • Page 117: Disposing Of Turbocharger Components

     Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  © Copyright 2014 ABB. All rights reserved.

  • Page 119: Spare Parts

     Turbocharger type  Serial number (HT……)  Description and part number Spare parts can be ordered from an official ABB Turbocharging Service Station. If different design versions have not been taken into consideration in  this document, please contact an ABB Turbocharging Service Station.
  • Page 120 Verbus Ripp® Washer 42058 / 42063 / 61043 / 61057 / 61058 Hexagon-head screw 42059 / 42064 / 61044 / 61056 / 61059 Hexagon nut 61037 Gasket 77005 O-ring seal (speed 86506 sensor) © Copyright 2014 ABB. All rights reserved.
  • Page 121 Work on turbine cleaning system should be carried out only by an  ABB Turbocharging service station. Quantity Description Part number Locking plate 51255 Nozzle 52208 Sleeve 52212 Locking plate 52213 Strain bolt 52217 52218 © Copyright 2014 ABB. All rights reserved.

  • Page 122: View Of The Turbocharger With Part Numbers

    Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of the turbocharger with part 12.2 Page 120 numbers 12.2 View of the turbocharger with part numbers 12.2 © Copyright 2014 ABB. All rights reserved.
  • Page 123 Compressor casing 72018 Washer 72027 Hexagon nut 72029 Stud 77000 Wall insert 77005 (in customer spare part set) O-ring 79000 Diffuser 81000 Filter silencer 82000 Radial air suction branch 82000 Axial air suction branch © Copyright 2014 ABB. All rights reserved.

  • Page 124: View Of Cartridge Group With Part Numbers Tpl65-A32 / -A33 / -A36

    Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of cartridge group with part 12.3 Page 122 numbers TPL65-A32 / -A33 / -A36 12.3 View of cartridge group with part numbers TPL65-A32 / -A33 / -A36 12.3 © Copyright 2014 ABB. All rights reserved.
  • Page 125 Verbus Ripp® Washer 42064 Hexagon-head screw 43002 (option with compressor wheel Plate cooling system) 43001 Partition wall 43005 O-ring 43006 O-ring 43007 O-ring 86505 Speed sensor 86506 (in customer spare part set) O-ring © Copyright 2014 ABB. All rights reserved.
  • Page 126 Operation Manual / TPL65-A32 / -A33 / -A36 + TPL69-A32 / -A33 Spare parts View of cartridge group with part 12.4 Page 124 numbers TPL69-A32 / -A33 12.4 View of cartridge group with part numbers TPL69-A32 / -A33 12.4 © Copyright 2014 ABB. All rights reserved.
  • Page 127 42064 (in customer spare part set) Hexagon-head screw 42155 (option with compressor wheel cooling Plate system) 43001 Partition wall 43005 O-ring 43006 O-ring 43007 O-ring 86505 Speed sensor 86506 (in customer spare part set) O-ring © Copyright 2014 ABB. All rights reserved.

  • Page 128: View Of Turbine Cleaning System With Part Numbers (Optional)

    Locking plate 52208 (in spare parts set) Nozzle 52212 (in spare parts set) Bush 52213 (in spare parts set) Locking plate 52217 (in spare parts set) Strain bolt 52218 (in spare parts set) © Copyright 2014 ABB. All rights reserved.
  • Page 129 ABB Turbo Systems AG Bruggerstrasse 71a CH-5400 Baden Switzerland...

This manual is also suitable for:

Tpl65-a33Tpl65-a36Tpl69-a32Tpl69-a33Tpl65-a32

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